How to create a tray ceiling (recessed): Conversion walkthrough

[Morakot]

This is a walkthrough for building a tray ceiling. The following two posts will show you how to convert your existing suspended ceiling into a recessed tray ceiling.

All basic building material was purchased in regular hardware and DIY stores in Thailand. The design is relatively simple and only requires: standard aluminium/ steel parts for suspended ceilings, regular dry walling material, and about ten expansion plugs and twelve nuts and bolts.

Edited January 19, 2014 by Morakot

[Morakot]

Cut existing suspended ceilings open (preferably inform spouse or cohabitants in advance)

• Use chalk string for marking; leave about 30-60 cm depending on room size and design
• Use a hacksaw to cut through the gypsum and an angle grinder to get quickly through the aluminium frame

Move remaining vertical suspension steel wires to the walls and suspend from the side

• Use expansion plugs if you have concrete walls or beams there

Suspend a new aluminium frame system about 5 cm below concrete ceiling

• Coil steel wires into secure hooks
• Hang aluminium battens upright in rows spaced about 50cm
• Cross with battens flat up

Connect upright battens with lower ceiling level with steel wires, exactly where tray walls will be

• Keep everything flush to your existing wall and ceiling structure
• Use flat springs to push again existing walls and ceiling to enhance sturdiness

Add vertical battens and secure with drywall screws

• Space as narrow as possible: ca. 40cm

Sort out existing "cowboy" electric wiring as needed

• Upgrade to required standards; ask relevant forum experts if necessary

Edited January 19, 2014 by Morakot

[Morakot]

Attach gypsum panels to your new frame structure (see some serious progress as you cover your structure)

• Start with top ceiling; push panels right against vertical battens
• Create an edge base on top of original ceilings by running battens along
• Cover top of original ceilings with gypsum panels
• Attach gypsum panels to vertical frame structure with screws; wedge between horizontal top and bottom panels
• Secure lower horizontal top panel with another batten in place, fix with nuts and bolts going through the entire "sandwich"

Build up lower ceiling width by creating a chamber

• Attach batten with drywall screws
• Cover top and double wall side

Tape all joints with jointing materials to be finished flush

• Fix original gypsum structure if necessary: e.g. cover holes or smooth edges

Skim render like a pro (and possible ask yourself why on earth you ever started this job)

Paint; keep all fittings wrapped (and confuse local builders as to what this is all about)

Install LED strips for top lighting; close access hatch

Install fan or chandelier as you fancy

• Increase fire resistance by covering back of polystyrene ceiling rosette with plaster of Paris
• If adding a ceiling fan (yes they do cool people with "hot" air) extent down rod to have blades below original ceiling height

Check everything, step back, open beverage and marvel or feel sorry at result

Edited January 19, 2014 by Morakot

[krisb]

Looks great Morakot, well done mate. You make these 'simple' steps sound so easy!

Are those LED strip lights?....correction, just read they are...They really set off ceilings like this.

Word of warning, any ceiling insulation needs to be kept 100mm away from any down lights. They get very hot and can start fires.

Edited January 20, 2014 by krisb

[Morakot]

Thanks for the support! !

The LED strips are actually dimmed, with a remote controlled DC dimmer. When the pictures were taken it was dimmed quite a bit and so mainly the coved area is highlighted. If you turn it up the entire ceiling will be more illuminated. You usually need quite some inward recess for your design to achieve this lighting effect.